Yarn bulking methods

ABSTRACT

A method of bulking yarn in package form comprises subjecting yarn in a substantially tensionless package to a heated fluid at a super atmospheric pressure. Also apparatus for performing the method and the bulked package.

United States Patent Pearce [541 YARN BULKING METHODS [72] Inventor:Larry N. Pearce, Oak Park, Ill.

[73] Assignee: Deering Milliken Research Corporation, Spartanburg, SC.

221 Filed: June 22, 1970 211 Appl.No.: 48,034

521 US. 01. .....2s/72 HR 51 1111. c1. ..D02g 1/00 58 Field of Search..28/72.1, 1.2, 21, 72 HR, 75,

[56] References Cited UNITED STATES PATENTS 1,560,575 11/1925 Hohmann..28/58 B 1,815,027 7/1931 Murch ..28/58 B 3,388,547 6/1968 Koga et a1..28/72. 17 x 1 Nov. 14, 1972 2,863,208 12/1958 Drummond et a1......28/72 SP 2,936,508 5/1960 Buddecke ..28/21 2,962,857 12/1960 Woodet a1. ..28/76 X 3,234,627 2/1966 Russo et al. ..28/21 3,289,440 12/1966 Buddecke ..28/21 X 3,425,110 2/ 1969 Willis ..28/75 WT FOREIGNPATENTS OR APPLICATIONS 835,050 9/1938 France ..28/58 B PrimaryExaminer-Louis K. Rimrodt Attorney-Norman C. Armitage and H. WilliamPetry [57] ABSTRACT A method of bulking yarn in package form comprisessubjecting yarn in a substantially tensionless package to a heated fluidat a super atmospheric pressure. Also apparatus for performing themethod and the bulked package.

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A LARRY N.PEARCE iww AT TORNEY YARN BULKING METHODS This inventionrelates to a novel method and apparatus for treating textile yarns toincrease the bulk thereof. More particularly, the invention relates to amethod and apparatus for bulking yarn in package form.

One commonly employed method for bulking yarns is the skein dyeingprocess. In skein dyeing the yarn to be bulked is wound into skein formfrom bobbins or cones and the skeins loaded on a large carrier bydraping the skeins over horizontally mounted poles. The carriers loadedwith skeins are placed in a dye bath to dye the yarn and tosimultaneously bulk the yarn. After the dyeing and bulking arecompleted, the skeins are centrifuged to extract excess liquid and thenbackwound into packages which are dried in an oven prior to shipping.

The present invention provides a novel method and apparatus for bulkingyarn in a wound package form with a high degree of uniformity along itslength. The invention also provides a novel method for providingpolyester yarns having a substantially higher degree of bulk than isachievable by the skeindyeing process. A further advantage of theinvention is the bulking in a package form suitable for subsequentpressure dyeing methods. Another advantage is the bulking of singlepackages which permits the bulking apparatus to be located adjacent thewinding apparatus.

A method of the invention for bulking yarn in package form comprisessubjecting yarn in a substantially tensionless package to a heated fluidat a super atmospheric pressure. Advantageously, the heated fluid ispassed through the yarn package from the inside to the outside thereofand preferably, the fluid flow is advanced along the length of thepackage from one end to the other. The fluid generally is an aqueousfluid and particularly steam.

Yarn packages suitable for bulking in accordance with the method of theinvention are packages in which the yarn is in a substantiallytensionless condition. In one yarn package configuration which may beemployed successfully, is disposed around a central core in a helicalpattern so that the yarn forms a package composed of an ascending seriesof loops in which the yarn is adjacent the core along one portion ofeach loop and adjacent the periphery of the package at another portionthereof. Examples of suitable patterns are shown in FIGS. 3-5 of Polaket al., US. Pat. No. 2,404,742, with the pattern of FIG. 5 beingpreferred.

The method of the invention will be described in greater detail withreference to the accompanying drawings, in which:

FIGS. 1-9 are schematic illustrations of one processing sequence of thebulking method of the invention;

FIG. is an exploded perspective view of one form of apparatus forperforming the bulking method of the invention;

FIG. 11 is an exploded perspective view of the ap paratus shown in FIG.10 during another step in the bulking method of the invention;

FIG. 12 is an enlarged side elevation of the apparatus shown in FIG. 10;

FIG. 13 is an enlarged sectional view of the dome portion of theapparatus shown in FIG. 10;

FIG. 14 is a sectional view taken along line l4l4 of FIG. 13; and

FIG. 15 is an enlarged partial top view of the package support takenalong line 1515 of FIG. 12.

As shown in FIGS. 1-9, yarn which is the form of a substantiallytensionless package 11 on a core 12 is positioned on a support or base13 with the core disposed over a movable nozzle 14. Below the package 11and surrounding the nozzle 14 is a plenum chamber 15. The basel3'includes a peripheral flange 17 which engages rim 18 of dome l9. Dome19 has a line 20 for introducing an inert gas into the dome and also apressure gauge 21. The dome also includes an inner conical portion 22. Aline 23 for exhausting gas from the vicinity of the package connects tobase 13. As shown in FIG. 2, the dome 19 is disposed over the package 11with cone 22 in contact with the package and flange 17 engaging rim 18to form a treating chamber. In FIG. 3, a flow of air is introducedthrough line 20 to pressurize the chamber. FIG. 4 shows the start of theheat treating step with a heated fluid, e.g., steam, being forced fromnozzle 14 into plenum chamber 15. This flow of steam into plenum chamber15 advantageously is performed prior to the beginning of the steamingstep to insure that the velocity of the steam and the temperature of thenozzle 14 are within operating limits before the steam contacts the yarnand the nozzle advances through the package 1 l as shown in FIG. 5. Thiscondition is particularly important with yarns such as polyester yarnswith which full bulking cannot ordinarily be achieved if partial bulkinghas taken place prematurely. Passing of the steam flow through thepackage causes the yarn to shrink and bulk and reduces the size ofthepackage as the nozzle advances therethrough. This is shown in FIGS. 5and 6. After the steaming step has been completed, the nozzle 14 iswithdrawn from the interior of the package as shown in FIG. 7 and a flowof inert gas I is introduced into the chamber through line 20. Any steamand condensate in the treating chamber is exhausted through line 23. Asshown in FIGS. 8 and 9, the flow of inert gas is continued as the dome19 is moved from around bulked package 11'. The'bulked package 11' isthen removed from the base 13, and the sequence is repeated with anewyarn package.

While the above-described sequence of operations, as shown in FIGS. 1-9of the drawings, is important to achieve a high degree of bulk withyarns which are difficult to bulk such as those including polyesterfibers, the sequence may be simplified for the processing of yarns whichbulk readily. For example, acrylic yarns may be bulked without theinitial pressurization with inert gas as shown in FIG. 3. Also, it isnot critical that the fluid treatment be done as the nozzle is movedthrough the core 12 of the package. For example, the heat treatment maybe accomplished when the nozzle 14 is in its upper position as shown inFIG. 6 of the drawings or the heated fluid may be introduced through gasline 20 and the nozzle eliminated. This simplification of the processingsequence generally is permissible with yarns that bulk easily and can bebulked successfully with known processes such as skein dyeing. However,as pointed out above, in the case of polyester yarns which cannot bebulked to a high degree by a skein dyeing process, it is preferred thatthe initial pressurization and the particular steaming sequenceutilizing a moving nozzle shown in FIGS. 4 and 5 of the drawings beemployed.

The processing sequence particularly suitable for the bulking ofpolyester yarn subjects the yarn to an inert gas at a super atmosphericpressure prior to the heat treating step. Suitable gases include air,nitrogen, carbon dioxide, argon and similar gases which are inert to theyarn. Both the inert gas and the succeeding hot fluid treatment areperformed at a super atmospheric pressure, for example, between about 2and 50 pounds per square inch gauge pressure and preferably betweenabout 5 and 25 psi. While the inert gas treatment generally is performedat ambient temperatures, the hot fluid treatment will be at an elevatedtemperature,

'usually between about 220 and 280 F.

Where the fluid treatment of the yarn package is accomplished while thenozzle advances through the package from one end to the other, it isdesirable that the nozzle have an orifice which will pass the fluidthrough the package from the inside to the outside thereof withsufficient velocity to uniformly bulk the package. For example, a steamflow rate between about 5 and 25 pounds per minute advantageously may beemployed.-Advantageously, the nozzle orifice deflects the fluid in aslightly downward or backward direction during the advance through thepackage.

One preferred form of apparatus for performing the bulking method of theinvention is shown in FIGS. -12 of the drawings. In FIG. 10, a yarnpackage 30 is positioned on a support 31 disposed above a base 32. Adome 33 is located concentrically with package 30 and movablelongitudinally into contact with base 32.

Movement of dome 33 is achieved with a cylinder 34 which is operativelyconnected thereto through bracket 35. The movement of the dome iscontrolled by a plurality of guide rollers 37 and 38 which contactsupport member 39. Support member 39 has an opening 41 therein forsafety stop piston 42 of cylinder 43. When dome 33 is in a positionsurrounding the yarn package 30, roller 38 engages a spring actuated rod44 with suitable projections which engage sensing switch 45.

Dome 33 has an air line 47 connected thereto to provide for the flow ofa gas into the dome cavity. Disposed within the upper portion-of thedome is a cone 48 which engages the upper portion of the yarn package 30when the dome surrounds the package. A weir 49 is positioned within thelower portion of the dome to collect any water condensing on the insidewalls of the dome. Rim 51 of the dome 33 includes a pair of cam surfaces52 for securing the dome to the base 32 through a locking ring assembly53. The locking ring assembly has a periphery which is movable by meansof cylinder 54 and a plate 55. A switch 56 is positioned adjacentcylinder 54 to sense movement thereof. Rollers 57 are mounted inassociation with the locking ring assembly 53 through brackets 58 forengagement with the cam surfaces 52 of the dome flange 51 when the lockring assembly is rotated to the closed position. A spring loaded lockingpin 59 is disposed for engagement with an opening in plate 55 when thelocking ring assembly 53 is in its closed position. A sensing switch 60is located adjacent locking pin 59.

A nozzle 61 is positioned in a central opening of base 32 as shown inFIG. 12. A seal 62 is disposed within the opening and bears against thesurface of the nozzle.

Nozzle 61 has a transverse opening 63 adjacent the end thereof throughwhich the fluid is emitted. in the normal rest or downward position ofthe nozzle 61, the transverse opening 63 is located within a plenumchamber 64 disposed below the base 32. Drains 65 are positioned aboutthe periphery of the base 32 to permit the removal of fluid and/orcondensate formed during the processing of the yarn. Fluid istransmitted to the nozzle 61 through a line 67 including a valve 68 asshown in FIGS. 10 and 11.

The nozzle is moved vertically during processing by a drive mechanismincluding chains 69 and sprockets 70 and 71. Sprockets 71 are'connectedthrough shaft 72 to pinion gear 73 which engages rack 74. Rack 74 isactuated by cylinder 75. The movement of nozzle 61 is guided by roller77 moving along guide rail .78. Guide roller 77 is connected to nozzle61 through a bracket 79. The action of cylinder is controlled by limitswitches 81 and 82 positioned to engage the guidebracket 79 at the upperand lower extremities of the noule movement.

In the operation of the apparatus shown in FIGS. 10-12, a yarn package30 is positioned on support 31, and suitable controls (not shown) areactuated causing piston 42 to withdraw from opening 41, removing thesafety stop from the path of dome 33 so that dome 33 is lowered by theaction of cylinder 34 into contact with base 32. When this contact isestablished roller 38 bears against connecting rod 44 to actuate switch45. Thereafter, cylinder 54 rotates locking ring assembly 53 so thatrollers 57 engage cam surfaces 52 of the dome flange 51. When thelocking ring assembly reaches its closed position, pin 59 engages anopening in plate 55 to lock the ring and base to the dome.

The processing cycle then is performed following the sequence shown inFIGS. 1-9 of the drawings. Progressive steaming is accomplished byactuating cylinder 75 which moves rack'74 and thereby rotates piniongear 73 and sprockets 71, moving chains 69 which are secured to bracket79. This movement raises the nozzle 61 and advances it through thecentral core of the package. The heated fluid is emitted from transverseopening 63 of the nozzle by valve .68 and through line 67. Uponcompletion of the heat treating step, the contact of switch 81 bybracket 79 reverses the action of cylinder 75 and rack 74 so thatsprockets 71 rotate in the opposite direction moving the nozzle 61 toits lower or normal rest position. After the inert gas has beenintroduced into the dome through line 47 and the condensate removedthrough drains 65, locking pin 59 is withdrawn and cylinder 54 isreversed unlocking ring assembly 53. Thereafter, the actuation ofcylinder 34 raises dome 33 to its most upward position and cylinder 43moves piston 42 into opening 41 to provide a safety stop againstaccidental dropping of the dome. This permits the bulked yarn package tobe removed from support 31. A new package then is inserted for bulkingand the operation repeated.

The above description and drawings show that the present inventionprovides a novel method and apparatus for bulking yarn in a tensionlesspackage configuration. Furthermore, the method of the invention resultsin a product having a high degree of bulk uniformity along the length ofthe packaged yarn. Moreover, the invention enables polyester yarn to bebulked to a substantially higher degree than is achievable by skeindyeing processes. Also, the bulked yarn package is suitable for use inpressure dyeing techniques. In addition, since the apparatus permits thebulking of single packages, the bulking apparatus may be locatedadjacent the package winding station. This minimizes the possibility ofdamages to the packages which have been wound in a loose, substantiallytensionless form.

From the above description and drawings, it will be apparent thatmodifications and variations may be made in the described method andapparatus within the scope of the present invention. For example,certain steps of the bulking method may be rearranged and/or eliminatedfor particular yarns. Also, movement of the dome and the nozzle may beachieved by other means. Therefore, the invention is to be limited onlyby the following claims.

That which is claimed is:

1. An improve method of bulking yarn in package form in a closed chamberdesigned to accommodate a single yarn package comprising the steps of:confining a package of yarn in said chamber, subjecting the package ofyarn to an inert gas above atmosphere pressure, introducing a heatedfluid into said chamber, passing said heated fluid through said yarnpackage from the inside to the outside thereof to bulk the yarn in saidyarn package and exhausting said heated fluid from said chamber.

2. The method of claim 1 wherein said inert gas and said heated fluid isat a super atmospheric pressure, said heated fluid being at atemperature of about 212 F.

3. The method of claim 2 wherein said heated fluid is steam.

wherein the fluid flow is advanced along the length of the package fromone end to the other.

5. A method of bulking yarn in package form according to claim 1 whereinthe heated fluid is steam.

6. A method of bulking yarn in package form according to claim 5 whereinthe steam is at a temperature between about 220 and 280 F.

7. An improved method of bulking a polyester yarn in package form in aclosed chamber designed to accommodate a single yearn package comprisingthe steps of: confining a package of yarn in said chamber, Subjectingthe closed chamber prior to heat treating, introducing a heated fluidinto said chamber to a super atmospheric pressure subjecting saidpackage of yarn to said heated fluid to bulk the yarn in said packageand exhausting said heated fluid from said chamber after subjecting saidpackage of yarn thereto.

8. The method of claim 7 wherein said heated fluid is steam.

9. The method of claim 8 wherein said steam is at a super atmosphericpressure.

10. A method of bulking yarn in package form according to claim 7wherein the heated fluid is an aqueous fluid.

11. A method of bulking yarn in package form according to claim 7wherein the heated fluid is steam.

12. A method of bulking yarn in package form according to claim 7wherein the heated fluid is water at a temperature above about 212 F.

"H050 UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent: No.3, 702 492 Dated November 14, 1972 Inventor(s) Larry N. Pearce It iscertified that error appear! in the above-identified patent and thatsaid Letters Patent are hereby corrected as shown below:

In Column 5, line 5, change "damages" to --damage--; line 18, w"improve" should read --improved--; line 22, "atmosphere" should be"atmospheric", In Column 6, line 12, change "yearn" to --yarn--; line14, "subjecting" should be subjecting--; line 14, after "chamber thephrase --to a super atmospheric pressure-- should be 7 added; line 15should be added after "chamber"; lines 15 and 16V delete the phrase "toa super atmospheric pressure".

Signed and sealed this 26th day of February 1971 (SEAL) Attestr C.MARSHALL DANN EDWARD M.FLETCHE1R,JR.

Commlssloner of Patents Attesting Officer

1. An improve method of bulking yarn in package form in a closed chamberdesigned to accommodate a single yarn package comprising the steps of:confining a package of yarn in said chamber, subjecting the package ofyarn to an inert gas above atmosphere pressure, introducing a heatedfluid into said chamber, passing said heated fluid through said yarnpackage from the inside to the outside thereof to bulk the yarn in saidyarn package and exhausting said heated fluid from said chamber.
 2. Themethod of claim 1 wherein said inert gas and said heateD fluid is at asuper atmospheric pressure, said heated fluid being at a temperature ofabout 212* F.
 3. The method of claim 2 wherein said heated fluid issteam.
 4. A method of bulking yarn according to claim 1 wherein thefluid flow is advanced along the length of the package from one end tothe other.
 5. A method of bulking yarn in package form according toclaim 1 wherein the heated fluid is steam.
 6. A method of bulking yarnin package form according to claim 5 wherein the steam is at atemperature between about 220* and 280* F.
 7. An improved method ofbulking a polyester yarn in package form in a closed chamber designed toaccommodate a single yearn package comprising the steps of: confining apackage of yarn in said chamber, Subjecting the closed chamber prior toheat treating, introducing a heated fluid into said chamber to a superatmospheric pressure subjecting said package of yarn to said heatedfluid to bulk the yarn in said package and exhausting said heated fluidfrom said chamber after subjecting said package of yarn thereto.
 8. Themethod of claim 7 wherein said heated fluid is steam.
 9. The method ofclaim 8 wherein said steam is at a super atmospheric pressure.
 10. Amethod of bulking yarn in package form according to claim 7 wherein theheated fluid is an aqueous fluid.
 11. A method of bulking yarn inpackage form according to claim 7 wherein the heated fluid is steam. 12.A method of bulking yarn in package form according to claim 7 whereinthe heated fluid is water at a temperature above about 212* F.